U.S. patent number 8,707,639 [Application Number 13/692,149] was granted by the patent office on 2014-04-29 for door lite frame with nestable frame components.
This patent grant is currently assigned to Masonite Corporation. The grantee listed for this patent is Masonite Corporation. Invention is credited to Douglas Thompson.
United States Patent |
8,707,639 |
Thompson |
April 29, 2014 |
Door lite frame with nestable frame components
Abstract
A door lite frame comprises a first frame component comprising
first screw bosses and first grip sockets, and a second frame
component comprising second screw bosses and second grip sockets.
The first and second frame components are constructed to permit
arrangement of the first and second frame components in an
assembled state and a nested state with respect to one another. In
the assembled state, the first screw bosses are correspondingly
aligned with the second screw bosses, and the first and second
frame components are secured to each other. In the nested state, at
least one of the first screw bosses of the first frame component is
mated with at least one of the second grip sockets of the second
frame component.
Inventors: |
Thompson; Douglas (Tampa,
FL) |
Applicant: |
Name |
City |
State |
Country |
Type |
Masonite Corporation |
Tampa |
FL |
US |
|
|
Assignee: |
Masonite Corporation (Tampa,
FL)
|
Family
ID: |
47459130 |
Appl.
No.: |
13/692,149 |
Filed: |
December 3, 2012 |
Prior Publication Data
|
|
|
|
Document
Identifier |
Publication Date |
|
US 20130139467 A1 |
Jun 6, 2013 |
|
Related U.S. Patent Documents
|
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
Issue Date |
|
|
61565719 |
Dec 1, 2011 |
|
|
|
|
Current U.S.
Class: |
52/204.7;
52/656.4; 49/505; 52/204.1; 52/213; 52/204.55; 52/204.65; 49/504;
52/656.9 |
Current CPC
Class: |
E06B
3/9681 (20130101); E06B 3/5892 (20130101); E06B
3/9636 (20130101); E06B 3/9642 (20130101); E06B
3/968 (20130101); E06B 1/36 (20130101); E06B
3/9684 (20130101); E06B 3/5864 (20130101); E06B
2003/6217 (20130101) |
Current International
Class: |
E06B
3/988 (20060101) |
Field of
Search: |
;52/204.5,204.53,204.55,204.65,204.1,211,204.593,204.7,212,782.1,213,215,656.4,656.9
;49/504,505 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Nguyen; Chi Q
Attorney, Agent or Firm: Berenato & White, LLC
Claims
What is claimed is:
1. A door lite frame comprising: a first frame component comprising
first screw bosses and first grip sockets, said first grip sockets
being formed by a first channel of ribs formed in said first frame;
and a second frame component comprising second screw bosses and
second grip sockets, said second grip sockets being fonmed by a
second channel of ribs formed in said second frame; said first and
second frame components constructed to permit arrangement of said
first and second frame components in an assembled state and a
nested state with respect to one another; wherein in said assembled
state, said first screw bosses being correspondingly aligned with
said second screw bosses, and said first and second frame
components being secured to each other; and wherein in said nested
state, at least one of said first screw bosses of said first frame
component mating with and received within at least one of said
second grip sockets of said second frame component.
2. The door lite frame as defined in claim 1, wherein in the nested
state, at least one of said second screw bosses of said second
frame component mating with at least one of said first grip sockets
of said first frame component.
3. The door lite frame as defined in claim 2, wherein each of said
first and second frame components has an exposed exterior side and
an interior side located opposite said exterior side.
4. The door lite frame as defined in claim 3, wherein said first
and second screw bosses outwardly extend from said interior side of
each of said first and second frame components, respectively.
5. The door lite frame as defined in claim 4, wherein said first
and second screw bosses are sized to receive frame fasteners for
joining said first and second frame components to one another.
6. The door lite frame as defined in claim 4, wherein said first
and second grip sockets are formed on said interior side of each of
said first and second frame components, respectively.
7. The door lite frame as defined in claim 6, wherein each of said
grip sockets of each of said first and second frame components is
spaced from and adjacent to one of said screw bosses of the same
one of said first and second frame components so that said grip
sockets of one of said first and second frame components are offset
from said screw bosses of another of said first and second frame
components when said first and second frame components are in the
assembled state.
8. The door lite frame as defined in claim 6, wherein said interior
side of each of said first and second frame components comprises a
pair of ribs both extending between said screw bosses substantially
parallel to each other.
9. The door lite frame as defined in claim 8, wherein each of said
grip sockets of each of said first and second frame components is
formed by opposite curvilinear portions of said parallel ribs, said
parallel ribs running parallel to each other along a first portion
and bulging out at a second portion to define said curvilinear
portions.
10. The door lite frame as defined in claim 9, wherein each of said
grip sockets of each of said first and second frame components is
dimensioned for frictionally receiving said screw bosses of another
of said first and second frame components.
11. The door lite frame as defined in claim 3, wherein each of said
first and second frame components further comprises a number of
glass supports outwardly extending from said interior side.
12. The door lite frame as defined in claim 3, wherein said
interior side includes a door engagement portion and a glass
engagement portion.
13. The door lite frame as defined in claim 1, wherein said first
and second screw bosses are substantially identical.
14. The door lite frame as defined in claim 13, wherein said first
and second grip sockets are substantially identical.
15. The door lite frame as defined in claim 1, wherein in the
nested state, at least one of said first screw bosses of said first
frame component corresponding with and frictionally received in at
least one of said second grip sockets of said second frame
component.
16. The door lite frame as defined in claim 15, wherein in the
nested state, at least one of said second screw bosses of said
second frame component corresponds with and is frictionally
received in at least one of said first grip sockets of said first
frame component.
Description
CROSS-REFERENCE TO RELATED APPLICATION
This application is related to U.S. Provisional Application Ser.
No. 61/565,719 filed Dec. 1, 2011 by Thompson, D., which is hereby
incorporated herein by reference in its entirety and to which
priority is claimed.
FIELD OF THE INVENTION
The present invention relates to frames for door lites in general
and, more particularly, to door lite frame components that are
nestable with one another.
BACKGROUND OF THE INVENTION
Doors, especially entry doors for residential and commercial
housing, often are provided with a partially or fully transparent
window-like glazing panel called a lite that may be made of, for
example, insulated glass or plastics, such as polycarbonate. Frames
for the door lites are typically used for maintaining the glazing
panel in place on the door. Typical door lite frames include two
frame components or halves that are positioned on opposite sides of
the glazing panel and fastened or otherwise interconnected to one
another and to the door to secure the glazing panel to the
door.
It is not convenient or efficient to transport assembled door lite
frames because they are relatively bulky and take up much room. It
is much more desirable to transport the door lite frames in an
unassembled state. However, doing so can cause damage to the door
lite frames in transport. With this in mind, it would be
advantageous to provide improved door lite frame components that
can be easily and cost-effectively nested together with one another
for convenient and safe transport.
SUMMARY OF THE INVENTION
A first aspect of the invention provides a door lite frame
comprising a first frame component including first screw bosses and
first grip sockets, and a second frame component including second
screw bosses and second grip sockets, with the first and second
components constructed to permit their arrangement in an assembled
state and a nested state with respect to one another. In the
assembled state, the first screw bosses are correspondingly aligned
with the second screw bosses, and the first and second frame
components are secured to one another. In the nested state, at
least one of the first screw bosses of the first frame component is
mated with at least one of the second grip sockets of the second
frame component, thus providing convenient and safe transportation
of the door lite frame components.
According to a second aspect of the invention, a door is provided
that features a door body having an opening therethrough, a door
lite frame secured to the door body so as to extend about a
periphery of the opening, and a glazing panel having a periphery
and positioned within the door lite frame so that the door lite
frame extends along the periphery of the glazing panel. The door
lite frame comprises a first frame component comprising first screw
bosses and first grip sockets, and a second frame component
comprising second screw bosses and second grip sockets. The first
and second frame components is constructed to permit arrangement of
the first and second frame components in an assembled state and a
nested state with respect to one another. In the assembled state,
the first screw bosses are correspondingly aligned with the second
screw bosses and the first and second frame components are adapted
to extend along the periphery of the glazing panel for securing the
glazing panel to the first and second door skins, while in the
nested state, at least one of the first screw bosses of the first
frame component is mated with at least one of the second grip
sockets of the second frame component.
Other aspects of the invention, including apparatus, systems,
methods, and the like which constitute part of the invention, will
become more apparent upon reading the following detailed
description of the exemplary embodiments and viewing the
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings are incorporated in and constitute a part
of the specification. The drawings, together with the general
description given above and the detailed description of the
exemplary embodiments and methods given below, serve to explain the
principles of the invention. In such drawings:
FIG. 1 is an elevational view of a door according to an exemplary
embodiment of the invention;
FIG. 2 is an exploded assembly drawing of the door of FIG. 1;
FIG. 3 is a perspective view of a door lite frame component of the
door of FIGS. 1 and 2;
FIG. 4A is an enlarged perspective view of a fragment of the door
lite frame component shown in a circle "A" of FIG. 3;
FIG. 4B is an enlarged perspective view of a fragment of the door
lite frame component shown in circle "B" of FIG. 3;
FIG. 4C is an enlarged perspective view of a fragment of the door
lite frame component shown in circle "C" of FIG. 3;
FIG. 4D is an enlarged perspective view of a fragment of the door
lite frame component shown in circle "D" of FIG. 3;
FIG. 4E is an enlarged perspective view of a fragment of the door
lite frame component shown in circle "E" of FIG. 3;
FIG. 5A is a front view of the door lite frame component of FIG.
3;
FIG. 5B is a rear view of the door lite frame component of FIG.
3;
FIG. 5C is a side view of the door lite frame component of FIG.
3;
FIG. 6A is an enlarged view of a fragment of the door lite frame
component shown in circle "F" of FIG. 5B;
FIG. 6B is an enlarged view of a fragment of the door lite frame
component shown in circle "G" of FIG. 5B;
FIG. 7A is a cross-sectional view of the door lite frame taken
along the sectional line 7A-7A of FIG. 5B;
FIG. 7B is a cross-sectional view of the door lite frame taken
along the sectional line 7B-7B of FIG. 5B;
FIG. 8 is a perspective view of first and second door lite frame
components in a nested state;
FIG. 9A is an enlarged perspective view of a fragment of the door
lite frame components in the nested state shown in circle "H" of
FIG. 8;
FIG. 9B is an enlarged perspective view of a fragment of the door
lite frame components of FIG. 8 separated from each other so that
screw bosses of one frame component are aligned with grip sockets
of the other frame component;
FIG. 10A is front view of the door lite frame components of FIG. 8
in the nested state;
FIG. 10B is a side view of the door lite frame components of FIG. 8
in the nested state;
FIG. 10C is an enlarged view of a fragment of the door lite frame
components in the nested state shown in circle "I" of FIG. 10B;
FIG. 11 is a perspective view of the door lite frame components of
FIG. 8 arranged in an assembled state;
FIG. 12A is a front view of the door lite frame components of FIG.
8 arranged in the assembled state;
FIG. 12B is a side view of the door lite frame components of FIG. 8
arranged in the assembled state;
FIG. 13A is an end side view of a plurality of sets of nested door
lite frame components stacked on one another; and
FIG. 13B is side view of the plurality of nested door lite frame
components of FIG. 13A.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS AND EXEMPLARY
METHODS
Reference will now be made in detail to exemplary embodiments and
methods of the invention as illustrated in the accompanying
drawings, in which like reference characters designate like or
corresponding parts throughout the drawings. It should be noted,
however, that the invention in its broader aspects is not limited
to the specific details, representative devices and methods, and
illustrative examples shown and described in connection with the
exemplary embodiments and methods.
This description of exemplary embodiments is intended to be read in
connection with the accompanying drawings, which are to be
considered part of the entire written description. In the
description, relative terms such as "horizontal," "vertical," "up,"
"down," "top" and "bottom" as well as derivatives thereof (e.g.,
"horizontally," "downwardly," "upwardly," etc.) should be construed
to refer to the orientation as then described or as shown in the
drawing figure under discussion. These relative terms are for
convenience of description and normally are not intended to require
a particular orientation. Terms concerning attachments, coupling
and the like, such as "connected" and "interconnected," refer to a
relationship wherein structures are secured or attached to one
another either directly or indirectly through intervening
structures, as well as both movable or rigid attachments or
relationships, unless expressly described otherwise. The term
"operatively connected" is such an attachment, coupling or
connection that allows the pertinent structures to operate as
intended by virtue of that relationship. Additionally, the word "a"
as used in the claims means "at least one".
FIGS. 1 and 2 of the drawings illustrate a door according to an
exemplary embodiment of the present invention indicated generally
by reference numeral 12. The door 12 includes a door body 14
provided with an opening for receiving a translucent panel (door
lite glass, glazing panel) 16, such as an impact-rated glass, and a
high-impact plastic door lite frame 30 extending along a periphery
16p of the translucent panel 16. The door 12 may be for
residential, business, or industrial use. Although illustrated as a
main exterior entry door with a panel design, it should be
understood that the door 12 may contain no panels, i.e., a flush
door. Further, the door 12 may comprise a patio door.
According to the exemplary embodiment of the present invention as
best illustrated in detail in FIG. 2, the door body 14 includes
first and second door skins (also known as door facings) 19 and 20,
respectively, top and bottom rails 17, and left and right stiles
18. The rails 17 and stiles 18 collectively define a rectangular
door frame having opposite first and second faces. The first and
second door skins 19 and 20 are secured to opposite faces of the
door frame. Typically, adhesive is used to secure the door skins 19
and 20 to the door frame. In the case of metallic (e.g., steel)
door skins 19 and 20, mechanical fastening and the like, for
example, may be used. Typically, the first and second door skins 19
and 20 are secured to each other so as to form a cavity
therebetween. The cavity of the door 12 optionally is filled with a
core material, such as expanded foam insulating material.
Additional or alternative core materials may be used.
Alternatively, the door 12 may be a solid core door.
The first and second door skins 19 and 20 may be molded from an
appropriate polymer material and have a thickness of, for example,
about 1 mm to about 4 mm. The selected material of the door skins
19 and 20 can be sheet molding compound (SMC) with reinforcement
(e.g., fiber glass, cellulosic material, etc.), metal (e.g.,
steel), wood, medium density fiberboard, high density fiberboard,
or other materials suitable for the contemplated use. The door
skins 19 and 20 may be made of the same or different materials. The
door skins 19 and 20 may be molded from such materials as
fiberglass reinforced plastics, pressed board, thermosetting
compounds (e.g., vinyl esters), thermoplastics (e.g.,
polypropylene, polystyrenes), cellulosic material and resin
composites, or other moldable materials. The outer surfaces of the
door skins 19 and 20 can be smooth or can have a simulated wood
grain. The depth of the wood grain optionally is about 0.05 mm to
about 0.2 mm. An inner surface of the door skins 19 and 20 may have
a relatively rough or textured surface to increase the surface area
for adhesion to the door frame. The roughened inner surface may
provide stronger bonds between the door skins 19 and 20, the foam
material, the rails 17, and the stiles 18.
The first and second door skins 19 and 20 are each provided with
respective openings 21 and 22 therethrough. The openings 21, 22 are
aligned with each other for defining the opening in the door body
14 and receiving the translucent panel (e.g., door lite) 16. While
the openings 21, 22 are shown in FIGS. 1 and 2 as possessing a
rectangular shape, they can have any configuration, provided that
the openings are complementary. For example, the first and second
door skins 19, 20 may be provided with the openings 21, 22 having a
configuration including a semielliptical portion and an integrated
rectangular portion. It would be apparent to one skilled in the art
that other configurations (e.g., circular, polygonal, random) may
be provided.
The translucent panel 16 may be high impact rated, and designed to
successfully pass Testing Application Standard 201-94 (TAS 201)
based on a missile velocity of 35 miles per hour and Testing
Application Standard 203-94 (TAS 203) based on a 9000-cycle regime
applied consecutively. The translucent panel 16 may be a
preassembled single or multiple (e.g., two) pane unit or cassette.
The panel 16 may include a peripheral rim surrounding the pane(s).
In the case of a multiple pane unit, the peripheral rim may serve
to seal the area between the panes. As referred to herein, the term
translucent includes materials which permit light to pass through
but diffuse the light so that persons, objects, etc. on the
opposite side are not clearly visible, and also includes
transparent materials which permit light to pass through with
sufficiently small or no diffusion so that persons, objects, etc.
on the opposite side are clearly visible. The translucent panel 16
may be comprised of any material known in the art, such as clear
glass, annealed glass, tempered glass and various plastics.
Additionally, the translucent panel 16 may be tinted or colored, or
possess tinted or colored components, as may be desired. The
translucent panel 16 may be designed in any configuration known in
the art, and may also be installed as a side lite, a transom lite,
or in a similar application.
The door lite frame 30 comprises two opposite frame components or
halves 32.sub.1 and 32.sub.2. The interior (or first) frame half
32.sub.1 and the exterior (or second) frame half 32.sub.2 are
configured to mate with each other in order to hold the translucent
panel 16 in place therebetween when assembled on the door 12. As
best shown in FIGS. 1 and 2, the first and second frame halves
32.sub.1, 32.sub.2 interconnect the door body 14 to the translucent
panel 16. According to the exemplary embodiment of the present
invention, the two door lite frame halves 32.sub.1 and 32.sub.2 are
substantially identical and collectively form the single door lite
frame 30. Alternatively, the first and second frame halves
32.sub.1, 32.sub.2 may have different ornamental designs, provided
that mating surfaces thereof are designed to mate up and nest as
described herein below.
In view of the structural similarities of the first and second door
lite frame halves 32.sub.1 and 32.sub.2, and in the interest of
simplicity, the following discussion will use a reference numeral
without a subscript number to designate both of the door lite frame
halves. For example, the reference numeral 32 will be used when
generically referring to the door lite frame halves 32.sub.1 and
32.sub.2 rather than reciting both reference numerals. Accordingly,
because the two door lite halves 32.sub.1 and 32.sub.2 are
structurally similar, only one of the door lite frame halves
32.sub.1 and 32.sub.2 will be described in detail hereinbelow.
The first and second frame halves 32.sub.1 and 32.sub.2 of the door
lite frame 30 may be connected to each other in two different
states: an assembled state and a nested state of the door lite
frame 30. In the assembled state, illustrated in FIGS. 11, 12A and
12B, the first and second frame halves 32.sub.1 and 32.sub.2 are
generally connected to each other so as to securely hold the
translucent panel 16 in place therebetween and form the door lite
frame 30 assembled on the door 12. In the nested state, illustrated
in FIGS. 8, 9A, 10A-10C, 13A and 13B, the first and second frame
halves 32.sub.1 and 32.sub.2 are usually temporarily directly
connected to each other in a nested manner so as to facilitate
storage and/or transportation of the frame halves 32.sub.1 and
32.sub.2. It should be understood that when elements are referred
to as being "directly connected" or "directly coupled," there are
no intervening elements present.
As illustrated in detail in FIGS. 3-7B, the door lite frame half
32, according to the exemplary embodiment of the present invention,
is a single integral piece formed by plastic injection molding of,
for example, polystyrene. Other suitable plastics or other
materials known in the art may be used. Further according to the
exemplary embodiment of the present invention, the frame half 32 is
generally rectangular in shape and comprises two pairs of opposite
frame members: substantially identical top and bottom frame members
33a and 33b, respectively, and also substantially identical right
and left side frame members 34a and 34b, respectively, shown in
FIGS. 3, 5A and 5B. The door lite frame half 32 has an exposed
exterior side 35 and an interior side 36 facing the door 12 and/or
the translucent panel 16 when assembled and located opposite the
exterior side 35. An exposed surface 35a of the exterior side 35
provides an ornamental appearance of the door lite frame half 32.
Appropriate shapes for the exterior surface 35a are known in the
art. Often, the surface is configured and/or textured to simulate
the appearance of wood molding. The interior side 36 of the frame
half 32 includes a door engagement portion 38 provided to engage
the door body 14, and a glass engagement portion 40 provided to
engage the translucent panel 16. Each of the door engagement
portion 38 and the glass engagement portion 40 defines a channel 39
and 41, respectively, facing the door 12 or the translucent panel
16, respectively. A caulk or other sealant may be installed within
the channels 39 and 41 (best shown in FIGS. 7A and 7B) to enhance
sealing against the door 12 or the translucent panel 16.
The interior side 36 of each of the frame halves 32, best
illustrated in FIGS. 3 and 5B, includes a number of substantially
identical, cylindrical screw bosses (or posts) 46 outwardly
extending from the interior side 36 of the door lite frame half 32
and sized to receive frame connectors (also referred to herein as
fasteners) for joining the first and second frame halves 32.sub.1
and 32.sub.2 to one another. It should be noted that if appropriate
the screw bosses of the first frame half 32.sub.1 (or first screw
bosses) are on occasion marked with the numeral character 46.sub.1,
while the screw bosses of the second frame half 32.sub.2 (or second
screw bosses) are on occasion marked with the numeral character
46.sub.2, as shown in FIGS. 8, 9A-10C, 12B, 13A and 13B. However,
in view of the structural similarities of the screw bosses 46.sub.1
and 46.sub.2 and in the interest of simplicity, the following
discussion will use the reference numeral 46 when generically
referring to the screw bosses rather than reciting two different
reference numerals 46.sub.1 and 46.sub.2 of the first and second
frame halves 32.sub.1 and 32.sub.2. As the frame half 32 is a
single-piece injection molded component, the screw bosses 46 are
integral with the frame half 32.
As illustrated in FIGS. 3, 4A, 4B, 4E, 5A, 5B, 6A, 6B, 8, 9A, 9B,
10A and 12A, the screw bosses 46.sub.1 of the interior (or first)
frame half 32.sub.1 are provided with through holes 47.sub.1 open
on both the exposed exterior side 35 and the interior side 36 of
the interior frame half 32.sub.1, while the screw bosses 46.sub.2
of the exterior (or second) frame half 32.sub.2 are provided with
blind holes 47.sub.2 open only on the interior side 36 of the
exterior frame half 32.sub.2. Moreover, the interior diameter of
the screw bosses 46 of the interior (first) frame half 32.sub.1
(i.e., the diameter of the through hole 47.sub.1) is slightly
larger than the interior diameter of the screw bosses 46 of the
exterior (second) frame half 32.sub.2 (i.e., the diameter of the
blind hole 47.sub.2). Thus, as noted above, the two door lite frame
halves 32.sub.1 and 32.sub.2 are substantially identical because
the only significant differences between them are: 1) the through
holes 47.sub.1 in the interior frame half 32.sub.1, and the blind
holes 47.sub.2 in the exterior frame half 32.sub.2, and 2) the
interior diameter of the screw bosses 46 of the interior frame half
32.sub.1 is slightly larger than the interior diameter of the screw
bosses 46 of the exterior frame half 32.sub.2.
As best illustrated in FIGS. 3 and 4C, each of the frame halves 32
further includes a number of generally identical glass supports 52
outwardly extending from the interior side 36 of the top and bottom
frame members 33a and 33b of the door lite frame half 32 in
parallel with the screw bosses 46 and provided to support the
translucent panel 16 within the assembled door lite frame 30, i.e.,
when the first and second frame halves 32.sub.1 and 32.sub.2 are
joined to one another.
In the assembled state of the door lite frame 30, as illustrated in
FIGS. 11, 12A and 12B, the screw bosses 46 of the opposite frame
halves 32.sub.1 and 32.sub.2 are complementary to and coaxial
(i.e., in registry) with each other so that distal ends of the
screw bosses 46 of the opposite frame halves 32.sub.1 and 32.sub.2
are facing each other. The screw bosses 46 of the opposite frame
halves 32.sub.1 and 32.sub.2 may be axially juxtaposed or separated
by a gap. Such an arrangement allows for the translucent panel 16
of varying thickness and construction to be accommodated through
the use of additional spacers or support pieces.
The opposite frame halves 32.sub.1 and 32.sub.2 are joined together
by screws extending through the screw bosses 46 of the both
opposite frame halves 32.sub.1 and 32.sub.2. The screw bosses 46 of
the frame half 32 are preferably situated at uniform (or,
alternatively, non-uniform) spaced intervals along each of the
frame members 33a, 33b, 34a and 34b of the door lite frame half 32.
In the illustrated embodiment of FIGS. 3 and 5B, four of the screw
bosses 46 are disposed at the intersection of the frame members
33a, 33b, 34a and 34b (i.e., corner bosses) and two of the
uniformly spaced screw bosses 46 are disposed on each of the frame
members 33a, 33b, 34a and 34b.
The interior side 36 of the frame half 32, best illustrated in
FIGS. 3-4E and 5B, comprises a pair of integrally molded
reinforcing ribs 42 and 44 both extending between the screw bosses
46 and around an entire perimeter of the frame half 32, i.e., along
the frame members 33a, 33b and 34a, 34b, substantially parallel to
each other. The ribs 42 and 44 provide enhanced structural
integrity for the frame half 32, and they also support the other
frame components discussed below. As the frame half 32 may be a
single-piece (monolithic) injection molded component, the ribs 42
and 44 are integral with the frame half 32 and with one another. As
best illustrated in FIGS. 6A and 6B, an outer diameter D.sub.1 of
each of the screw bosses 46 is larger than a distance k between the
parallel ribs 42 and 44.
Each frame half 32 further includes a number of substantially
identical, cylindrical grip sockets 48 each formed on the interior
side 36 of the frame half 32 by curvilinear portions of the
parallel ribs 42, 44. It should be noted that if appropriate the
grip sockets of the first frame half 32.sub.1 could be defined as
first grip sockets, while the grip sockets of the second frame half
32.sub.2 could be defined as second grip sockets. Each of the grip
sockets 48 is spaced from but adjacent to the one of the screw
bosses 46. In other words, the grip sockets 48 of one of the frame
halves 32 are offset from the screw bosses 46 on another frame half
32 when the screw bosses 46 of the first and second frame halves
32.sub.1, 32.sub.2 are engaged, i.e., when the first and second
frame halves 32.sub.1, 32.sub.2 are in the assembled state.
According to the exemplary embodiment of the present invention, as
illustrated in FIGS. 3 and 5B, only one pair of the opposite frame
members, i.e., the top and bottom frame members 33a and 33b, is
provided with the grip sockets 48. Moreover, the number of the grip
sockets 48 provided on a particular frame member, e.g., 33a, may be
greater than the number of the screw bosses 46 provided on that
same frame member, as shown with respect to frame member 33a in
FIG. 5B.
Although, the screw bosses 46 and the grip sockets 48 are described
and shown in the accompanying drawings as being substantially
cylindrical, it will be appreciated that that the screw bosses 46
and the grip sockets 48 may be of any other appropriate
configuration, such as oval, rectangular, hexagonal, triangular,
etc.
As illustrated in detail in FIGS. 6A and 6B, each of the grip
sockets 48 is formed by two opposite curvilinear portions 50a and
50b of the opposite parallel ribs 42 and 44, respectively.
Moreover, each of the grip sockets 48 of one of the frame halves 32
is dimensioned for frictionally receiving the screw boss 46 of
another frame half 32. Specifically, a maximum distance D.sub.2
between the opposite semi-cylindrical portions 50a and 50b of each
of the grip sockets 48 (i.e., the diameter of the grip socket 48)
is slightly smaller than the outer diameter D.sub.1 of each of the
screw bosses 46 so as to provide a friction-fit connection between
the screw bosses 46 of one (the first or second) frame half
(32.sub.1 or 32.sub.2) and the grip sockets 48 of another (the
second or first) frame half (32.sub.2 or 32.sub.1). According to
the present invention, the number of the screw bosses 46 on one of
the first frame half 32.sub.1 is equal to the number of the screw
bosses 46 on the opposite, second frame half 32.sub.2, while the
number of the grip sockets 48 on the top and bottom frame members
33a and 33b is bigger than the number of the screw bosses 46.
The first and second frame halves 32.sub.1 and 32.sub.2 may be
connected to one another in either the assembled state or the
nested state. In the assembled state, the rectangular frame halves
32.sub.1 and 32.sub.2 are aligned with and overlie one another. In
the nested state, the rectangular frame halves 32.sub.1 and
32.sub.2 are slightly offset from one another.
In the assembled state, shown in FIGS. 1, 11, 12A and 12B, the
first and second frame halves 32.sub.1, 32.sub.2 are oriented
opposite relative to each other so that the interior side 36 of the
first frame half 32.sub.1 faces the interior side 36 of the second
frame half 32.sub.2 and the screw bosses 46 of the first and second
frame halves 32.sub.1, 32.sub.2 are aligned with one another. The
first and second frame halves 32.sub.1 and 32.sub.2 are fastened to
each other in the assembled position by screws extending through
the through hole 47.sub.1 in the first (interior) frame half
32.sub.1 and the blind hole 47.sub.2 in the screw bosses 46 of the
second (exterior) frame half 32.sub.2. Because the frame 30 is
sized to fit snugly in the openings of the door skins 19, 20, and
to receive the glazing member 16 between the frame halves 32.sub.1
and 32.sub.2, the frame 30 effectively interconnects the door body
14 to the glazing member 16.
In the nested state, shown in FIGS. 8, 9A, 9B and 10B, the first
and second frame halves 32.sub.1, 32.sub.2 are oriented relative to
each other so that at least one, and optionally a plurality (but
not all), of the screw bosses 46 of one of the frame halves 32 are
mated with the corresponding number of the second grip sockets 48
of another (opposite) of the frame halves 32. Specifically,
according to the exemplary embodiment of the present invention, the
screw bosses 46 of one of the frame halves 32 are frictionally
received in the grip sockets 48 of another of the frame halves 32
so as to provide a friction-fit connection between the first and
second frame halves 32.sub.1 and 32.sub.2. Further specifically, in
the nested state, one or more (but not all) of the first screw
bosses 46.sub.1 of the first frame half 32.sub.1 correspond with
and are frictionally received in one or more of the second grip
sockets 48.sub.2 of the second frame component 32.sub.2. At the
same time, one or more (but not all) of the second screw bosses
46.sub.2 of the second frame half 32.sub.2 correspond with and are
frictionally received in one or more of the first grip sockets
48.sub.1 of the first frame component 32.sub.1. To do so, first,
the first and second frame halves 32.sub.1, 32.sub.2 are oriented
relative to each other so that the interior side 36 of the first
frame half 32.sub.1 faces the interior side 36 of the second frame
half 32.sub.2 and the screw bosses 46 of the first and second frame
halves 32.sub.1, 32.sub.2 are aligned with one another. Next, one
of the frame halves 32 is moved in translation (i.e., along the
straight line) relative to another frame half 32 within its own
plane and along the top and bottom frame members 33a and 33b (that
is, widthwise and lengthwise) so that at least one of the screw
bosses 46 of one of the frame halves 32 is aligned with a
corresponding grip sockets 48 of another frame half 32. Because the
number of the grip sockets 48 on the top and bottom frame members
33a and 33b is bigger than the number of the screw bosses 46, one
of the frame halves 32 can be conveniently shifted relative to
another frame half 32 within its own plane widthwise in any of the
opposite directions (i.e. either left or right). As shown in FIG.
9B, multiple screw bosses 46 and grip sockets 48 are aligned. Then,
one of the frame halves 32 is moved toward the other of the frame
halves 32 (or both frame halves are moved) so that the one or more
screw bosses 46 of one of the frame halves 32 are frictionally
engaged in the aligned one or more grip sockets 48 of another of
the frame halves 32, thus providing the friction-fit connection
between the first and second frame halves 32.sub.1 and 32.sub.2, as
shown in FIGS. 8, 9A, 10A and 10B. Moreover, the screw bosses 46
nested in the grip sockets 48 also prevent warping of the frame
halves 32 during the storage and/or transportation.
The depth W.sub.N of the door lite frame 30 in the nested state,
shown in FIG. 10C, is substantially smaller than the depth W.sub.A
of the door lite frame 30 in the assembled state, shown in FIG.
12B. For example, in one embodiment, the depth W.sub.A of the door
lite frame 30 in the assembled state equals 2.427'', the depth
W.sub.N thereof in the nested position equals 1.427'', or 1'' less.
Accordingly, the door lite frame in accordance with the exemplary
embodiments significantly reduces the shipping/storing size of the
stacked-up door lite frames shown in FIGS. 13A and 13B.
As best illustrated in FIGS. 3, 4D, 8, 10B, 12B and 13B, each of
the right and left side frame members 34a and 34b of at least one
of the frame half 32 further includes two generally identical
anti-twist supports 54 outwardly extending from the interior side
36 of the right and left side frame members 34a and 34b of the door
lite frame half 32. The supports 54 are provided to prevent
twisting of the first and second frame halves 32.sub.1 and 32.sub.2
when the first and second frame halves 32.sub.1 and 32.sub.2 are
joined to each other, such as during frame assembly.
Therefore, the first and second frame halves of the exemplary door
lite frame embodied herein can be easily and cost-effectively
nested together when transported and/or stored, thereby lowering
transportation/storage costs by reducing the shipping/storing size,
and preventing warping of the frame halves during the storage
and/or transportation.
The foregoing description of the exemplary embodiments of the
present invention has been presented for the purpose of
illustration in accordance with the provisions of the Patent
Statutes. It is not intended to be exhaustive or to limit the
invention to the precise forms disclosed. Obvious modifications or
variations are possible in light of the above teachings. The
embodiments disclosed hereinabove were chosen in order to best
illustrate the principles of the present invention and its
practical application to thereby enable those of ordinary skill in
the art to best utilize the invention in various embodiments and
with various modifications as are suited to the particular use
contemplated, as long as the principles described herein are
followed. Thus, changes can be made in the above-described
invention without departing from the intent and scope thereof. It
is also intended that the scope of the present invention be defined
by the claims appended thereto.
* * * * *